Load distributing apparatus for corner posts

ABSTRACT

An apparatus for distributing a load placed on top of a packaging unit is provided. The apparatus includes a set of molded plastic caps that fit over the upper ends of corner posts and a rectangular top frame mountable to the caps to evenly distribute the load across the entire cross sectional profile of the corner posts to prevent one or more of the posts from buckling or otherwise failing.

BACKGROUND

1. Field of the Invention

This patent relates to a palletized packaging assembly. More particularly, this patent relates to a packaging assembly comprising vertical support posts and including means for distributing a stacking load that minimizes the buckling effect that can occur due to offstacking.

2. Description of the Related Art

Articles such as outside air conditioners or large household appliances (washers, dryers, ranges, etc.) are often packaged and shipped in packaging units in which the article rests on a transport base and is enclosed by a box or carton, and in which vertical support posts are inserted between the article and the carton. The support posts are generally located adjacent the four interior corners of the carton (and thus may be referred to as corner posts) and typically extend from the transport base to the top of the carton. The posts not only to protect the article from lateral impact forces but also to provide axial (vertical) stacking strength. Loads placed on top of the packaged article are borne by the support posts and not by the packaged article.

When packaged units are not stacked in perfect vertical alignment (a phenomenon referred to as “offstacking”), the corner posts bearing the brunt of the offstacked load are more likely to fail (buckle) due to a less than optimal distribution of the load (stacking weight) on the corner post walls. At best, offstacking can result in a slight crimping of the carton. At worst, offstacking can result in the collapse of stacked units.

Thus the primary object of the present invention is to provide a packaging system that prevents support post buckling due to offstacking.

Another object of the invention is to provide a shipping package in which a load placed on top of a packaged unit is distributed more evenly across the support post walls.

Further and additional objects will appear from the description, accompanying drawings, and appended claims.

SUMMARY OF THE INVENTION

The present invention is an apparatus for distributing a load placed onto a packaging unit of the kind having a base upon which the packaged article rests and is transported, a box or carton enclosing the article on four sides and on top, and support posts extending vertically upward from the base to protect the article from lateral impact forces and to provide stacking strength. The apparatus functions to distribute a load placed on top of the packaging unit more evenly across the walls of the four corner posts, thereby minimizing buckling that can occur when a load is offstacked.

The apparatus comprises a plurality of support post fittings or caps that mount onto the top ends of the support or corner posts, and a top frame that fits onto the caps. Each cap comprises a platform and means for mounting the cap onto the top end of the corner post. The mounting means may comprise a sidewall extending downwardly from the platform and configured to enclose at least a portion of the support post. The cap sidewall may partially or completely enclose the upper end of the support post and, preferably, forms a friction fit with the support post.

The top frame is configured to rest securely on the cap platforms and has an upper, load bearing surface. The top frame may comprise front and rear horizontal crossbeam members and side crossbeam members connected at their respective ends to form a rectangular structure. Weight from a load placed on the upper, load bearing, surface of the top frame is distributed throughout the top frame and along the entire end wall surface of the corner posts.

In essence, the corner posts and top frame form a protective cage around the packaged article, not only protecting the article from lateral impact forces, particularly at the four vertical corners of the package, but also protecting the article from compression forces from other packaged units stacked on top, even when those other units are offstacked.

THE DRAWINGS

FIG. 1 is an exploded view of a palletized packaging assembly including a load distributing apparatus according to the present invention.

FIG. 2 is a top perspective view of a support post cap which is a component of the load distributing apparatus of FIG. 1.

FIG. 3 is a bottom perspective view of the support post cap of FIG. 2.

FIG. 4 is a perspective view of a packaging assembly similar to that of FIG. 1 with the carton shown in phantom lines to better show the load distributing apparatus of the present invention.

FIG. 5 is a partial close up view of the load distributing apparatus of FIG. 5.

FIG. 6 is a cross sectional view taken along line 6-6 of FIG. 5.

FIG. 7 is a bottom perspective view of an alternative embodiment of a support post cap according to the present invention.

FIG. 8 is a top perspective view of the support post cap of FIG. 7.

FIG. 9 is an exploded view of a cap, top frame and shipping pallet assembly, illustrating an alternative use of the caps and top frame of the present invention.

FIG. 10 is a perspective view of the cap, top frame and shipping pallet assembly of FIG. 9 shown assembled.

DETAILED DESCRIPTION OF THE INVENTION

While this invention may be embodied in many forms, there is shown in the drawings and will herein be described in detail one or more embodiments, with the understanding that this disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the invention to the illustrated embodiment(s).

Turning to the drawings, there is shown in FIG. 1 an exploded view of a packaging assembly 10 incorporating the load distributing apparatus of the present invention. The packaging assembly generally comprises a base 18 upon which a packaged article 50 rests, a box or carton 34 enclosing the article 50 of its four sides, and support posts 17 inserted between the packaged article 50 and the carton 34. The support posts 17 are located adjacent the four interior corners of the carton 32 (and thus may also be referred to as corner posts) and extend from the base 18 to the near the top of the carton. The corner posts 17 protect the article 50 from lateral impact forces and provide axial (vertical) stacking strength for the entire unit 10. Loads placed on top of the packaged article 10 are borne by the support posts 17 as explained further below.

The article 50 to be packaged can be any large article, such as the air conditioning unit depicted in FIG. 1. The article 50 typically rests on the transport base 18 during manufacture, with the transport base 18 ultimately functioning as the bottom of the carton 32. The assembled unit 10 may be placed on a shipping pallet 12 to enable the unit 10 to be moved by fork lift truck or other means.

As described in more detail in a co-owned and co-pending patent application, the carton 32 and transport base 18 may be secured to the shipping pallet 12 by wedging the carton 32 and transport base 18 between two opposing end stops 16 which form part of the shipping pallet 12, and by securing the carton side bottom flaps 38 and transport base side panels 28 to the sides of the shipping pallet 12.

Still referring to FIG. 1, the shipping carton 32 comprises four vertical side walls 34, top flaps 40 and four relatively narrow bottom flaps 36, 38. The bottom flaps 36, 38 comprise front and rear flaps 36 and side flaps 38 and do not function as the carton bottom, at least not by themselves. Rather, the carton front and rear flaps 36 cooperate with the transport base 18 to form the carton bottom. More specifically, in the assembled packaging unit 10, the carton front and rear flaps 36 are tucked under the transport base 18 between the transport base 18 and the shipping pallet 12 while the side flaps 38 extend downward in roughly the same plane as the carton side walls 34 and are stapled to the pallet runners 15.

The corner posts 17 shown in FIG. 1 are disposed within the carton 32 adjacent the inner corners of the carton 32 to provide for corner impact protection and axial strength. The corner posts 17 can be convolutely wound paperboard corner posts of the type manufactured and marketed by Sonoco Products Company of Hartsville, S.C. However, any suitable support structures may be used for corner impact protection and axial strength, including without limitation angle board.

The invention is a system for distributing a load placed on top of the packaging unit 10 more evenly across the entire end wall surface of the corner posts. More specifically, the invention comprises a set of caps 19 and a top frame 21 that help spread a load placed on top of the unit 10 across the entire cross sectional profile of a set of vertical support posts 17, thereby helping to prevent one or more of the posts 17 from buckling or otherwise failing.

FIGS. 2 and 3 are top and bottom perspective views respectively of a support post cap 19 according to the invention. The cap 19 may be made from molded plastic or any suitable material, and comprises a platform 52, a sidewall member 54 extending downwardly from at least a portion of the platform periphery and configured to enclose a top portion of a support post 17, and an upper wall member 56 extending upwardly from the periphery of the platform 52 for retaining the top frame 21.

The shape of the support post cap 19 and, in particular, the platform 52, is determined to a large extent by the cross sectional shape of the corner posts 17. For example and without limiting the invention, in the illustrated embodiment the platform 52 is substantially L-shaped to conform to the L-shaped cross-sectional profile of the corner posts 17. The platform 52 should be in contact with as much of the end wall surface of the corner posts 17 as possible, and preferably with the entire end wall surface. The periphery of the cap 19 in FIGS. 2-3 includes an outer edge 53 defining a right angle and an arcuate (curved) inner edge 55, again substantially conforming to the cross-sectional shape of the corner post.

Preferably, the caps 19 form a friction fit with the top ends of the corner posts 17. As shown in FIG. 3, optional ribs 58 extend inwardly from the sidewall member 54 at locations corresponding to inwardly extending corner posts beads 60 to further secure the support post cap 19 to the support post 17. As shown in FIG. 6, the ribs 58 may extend inwardly far enough such that the free end of each rib abuts the outside of the corresponding bead apex 61, thereby adding to the friction fit.

FIG. 4 is a perspective view of a packaging assembly 10 with the carton 32 shown in phantom lines to better illustrate the load distribution apparatus of the present invention. The top frame 21 is substantially rectangular and has four corners, each corner being mounted onto one of the four support post caps 19. The top frame 21 comprises front and rear horizontal crossbeam members 62 and side crossbeam members 64 joined at their respective ends to form a rectangular frame-like structure. The top, load bearing surface of the top frame 21 is defined by the front and rear cross members 62, although other configurations are possible, including one in which the crossbeam members 64 are part of the load bearing surface.

One or more optional center cross beam members 66 may be incorporated into the top frame 21 for added strength. The cross beam members 66 may extend from one side cross beam 64 to the other intermediate the front and rear crossbeams 62, or from the front crossbeam 62 to the rear cross beam 62 intermediate the side cross beams 64.

The underside of the top frame 21 may be planar or have any suitable shape that forms a cooperative fit with the support post caps 19.

FIG. 5 is a close up view of a corner of the top frame 21 shown fitted onto one of the support post caps 19. The corner of the top frame 21 rests on the cap platform 52 and fits snugly against the cap upper wall member 56. The cap 19 fits snugly on the top of a corner post 17 such that the top end wall surface of the corner post 17 (i.e., the top edge of the corner post) abuts the underside of the platform 52.

FIGS. 7 and 8 are bottom and top views of an alternative embodiment of a support post cap 69 useful in the present invention. Like the cap 19 shown in FIGS. 2 and 3, this alternative support post cap 69 comprises a platform member 72 on which the top frame 21 is mounted, a sidewall member 74 extending downwardly from the outer periphery of the platform 72 for partially enclosing the top portion of a corner post 21, and an upper wall member 76 extending upwardly from the outer periphery of the platform 72. Unlike the cap 19 shown in FIGS. 2, 3 and 6, this alternative embodiment 69 comprises nubs or projections 68 extending downwardly from the underside of the platform 72. The nubs 68 extend into the hollow areas of the corner post 17 and are intended to help seat the cap 69 onto the corner post 17.

FIGS. 9 and 10 illustrate an alternative use of the caps 69 of the present invention wherein they are used to lock a frame 81 into a shipping pallet 82 placed on top of the frame 81 to aid in egress as the article 50 (not shown) moves down an assembly line. As shown in the figures, the caps 69 are inverted so that the nubs 68 are projecting upward, helping to seat the shipping pallet 82 onto the caps 69. The caps 69 are fitted onto the top surface of the four corners of the frame 81. The shipping pallet 82 is then seated onto the “nub side” of the four caps 69. The caps 69, frame 81 and shipping pallet 82 lock together. Where the frame 81 is part of a packaging unit 10 such as that shown in FIG. 1, the structure shown in FIGS. 9 and 10 can be used to secure one unit 10 on top of another 10 to prevent offstacking.

The palletized packaging assembly 10 of the present invention may be assembled and used in the following manner.

First, the composite transport base 18 is assembled by positioning the cushioning elements 30 on the bottom panel 20 as shown in FIG. 1, then folding the front and rear panels 26 up and over the cushioning elements 30 to form the transport base 18 shown in FIGS. 4 and 5. The side panels 28 may be left extending outward approximately within the same plane as the bottom panel 20.

Next, the article 50 to be assembled and transported is placed on the transport base 12, typically as the article 50 moves along a manufacturing assembly line. In the illustrated embodiment, the article is an outdoor air conditioning unit 50 having an embossed (protruding) bottom (not shown) that fits within the three dimensional space defined by the cushioning elements 30 and the bottom panel 20. The air conditioner frame or housing rests on the top walls 29 covering the cushioning elements 30. The transport base top panels 29 are thus positioned underneath the article 50 while the transport base side panels 28 remain extended outward.

Next, an open bottomed shipping carton 32 is placed over the article 50 and the transport base 18. At this stage in the assembly of the final packaging unit 10 the carton bottom flaps 36, 38 may be splayed outward as shown in FIG. 8.

The corner posts 17 and caps 19 are then inserted adjacent the inside corners of the carton 32 between the carton 32 and the article 50. The top frame 21 is then secured to the corner post top caps 19. The corner posts bottom ends rest on the transport base bottom panel 20 near the corners of the bottom panel 20. The corner posts 17, top caps 19 and top frame 21 together extend the full height of the carton 32.

As the article 50, carton 32 and transport base 18 continue to move along the conveyor line the carton front (leading) and rear (trailing) flaps 36 may be automatically folded underneath the transport base 18 and may or may not be secured to the underside of the transport base bottom panel 20. The carton side flaps 38 remain splayed outward, overlaying the still outwardly extending transport base side panels 28.

At the end of the conveyor line the article 50, carton 32 and transport base 18 are lifted up together and placed on a shipping pallet 12. The carton 32 and transport base 18 are wedged between the front and rear stops 16 of the shipping pallet 12 as shown in FIGS. 9 - 12 to prevent forward and rearward movement of the carton 32 and transport base 18. As best shown in FIGS. 9 and 11, the carton front and rear bottom flaps 36 remain folded under the transport base 18 and are interposed (sandwiched) between the transport base 18 and the shipping pallet 12.

The carton side flaps 38, which have been splayed outward over the transport base side panels 28 as shown in FIG. 10, are then folded downward so that the transport base side panels 28 are interposed between the pallet side runners 15 and the carton side flaps 38 as shown in FIG. 12. The carton side flaps 38 and side panels 28 are then removably secured to the shipping pallet runners 15 by staples 42 or other means.

Finally, the carton top flaps 40 are folded together until they flat against the top surface of the top frame 21 to complete the packaging assembly 10. The finished packaging assembly 10 is unitary in the sense that the carton 32, transport base 18 and shipping pallet 12 are secured together by the staples 42 and, to a lesser extent, by the fit of the carton 32 and transport base 18 between the shipping pallet end stops 16. The corner posts 17, caps 19 and top frame 21 extend from the transport base bottom panel 20 to the carton top flaps 40 and provide sufficient axial (vertical) strength to allow other packaging units 10 to be stacked on top.

Thus there has been described a packaging assembly 10 that can be stored and moved in stacked arrays. In a key aspect of the invention the caps 19 and top frame 21 distribute the load from units 10 stacked on top over the entire end wall surface of the corner posts 17 to prevent the posts 17 from buckling. The caps 19 may be made from molded plastic and the top frame 21 may be made from paperboard or wood. Of course, any suitable materials may be used for the caps and top frame, as well as the other packaging components.

It is understood that the embodiments of the invention described above are only particular examples which serve to illustrate the principles of the invention. Modifications and alternative embodiments of the invention are contemplated which do not depart from the scope of the invention as defined by the foregoing teachings and appended claims. It is intended that the claims cover all such modifications and alternative embodiments that fall within their scope. 

1. An apparatus for distributing a load stacked on top of a packaging unit across support post walls, the packaging unit comprising a base and support posts extending vertically upward from the base and terminating in a top edge, the apparatus comprising: a plurality of support post caps, each support post cap comprising a platform configured to contact the top edge of one of the support posts, and means for mounting the support post cap onto the support post; and a top frame configured to extend between the support post caps and to rest securely on the cap platforms, the top frame having an upper surface for bearing the load stacked on top of the packaging unit.
 2. The apparatus of claim 1 wherein the cap mounting means comprises a sidewall extending downwardly from the platform and configured to enclose at least a portion of the support post.
 3. The apparatus of claim 2 wherein the platform has a periphery and the sidewall extends downwardly from at least a portion of the platform periphery.
 4. The apparatus of claim 2 wherein each support post cap further comprises one or more ribs extending from the sidewall member to further secure the support post cap to the support post.
 5. The apparatus of claim 1 wherein the support post caps form a friction fit with the support posts.
 6. The apparatus of claim 1 wherein the platform is configured to contact the entire top edge of one of the support posts.
 7. The apparatus of claim 6 wherein each support post cap further comprises an upper wall member extending upwardly from the platform 52 for retaining the top frame.
 8. The apparatus of claim 1 wherein the top frame is substantially rectangular and has four corners, each corner being mounted onto one of the support post caps.
 9. The apparatus of claim 1 wherein the top frame comprises front and rear horizontal crossbeam members and side crossbeam members joined at their respective ends to form a rectangular frame-like structure.
 10. The apparatus of claim 9 wherein the upper, load bearing surface of the top frame is defined by the front and rear cross members.
 11. The apparatus of claim 1 wherein each support post cap comprises projections extending downwardly from the underside of the platform.
 12. The apparatus of claim 11 wherein the projections are configured to extend into hollow areas of a support post.
 13. The apparatus of claim 1 wherein the support post caps are molded plastic.
 14. An apparatus for supporting stacked loads comprising: a base; support posts sitting on the base and extending upward toward a load bearing second base, each support post having a top end comprising an upper cross section; and a load support cap attached to each vertical post top end and covering the upper cross section; wherein the second base sits on the caps; and wherein the load borne by the second base is distributed over the upper cross sections of the vertical posts.
 15. An apparatus for distributing a load stacked on top of a packaging unit, the apparatus comprising: a top frame having four corners; molded plastic caps configured to fit onto the four corners of the top frame; and a shipping pallet seated onto the caps.
 16. The apparatus of claim 15 wherein the caps comprise upwardly projecting nubs that help seat the shipping pallet onto the caps. 